Electronic arc welder



E. M. CALLENDER- ELECTRONIC ARC WELDER Sept. 2, 1947. 2,426,964

Filed July 15, 1944; s Sheets- Sheet 1 FIG. 1 1 2 INVENTOR EDWlN M. CALLENDER Sept 2, 1947. v E. M. CALLENDER 2,426,964

' I ELECTRONIC ARC WELDER Filed July 15, 194A 3 Sheets-Sheet 2 v INVENTOR EDWIN M. CALLENDE;

ATTORNEY Sept. 2, 1947- E. M. CALLENDER 2,426,964

ELECTRONIC ARC WELDER I Filed July 15, 1944 3 sheets sheer; 5

mm: 7 A

- I-ARC (AVERAGE) I- PRIMARY FIG. 5

v E- SOURCE .E- SOURCE 1- PRIMMLY I IARC (AVERAGE) VOLTS AMPERES I- Rmmmzv Evans F166 HM.

INVENTOR EDWIN M. CALLENDER BY 140 144 ATTORNEY Fatented Sept. 2,1947 i UNITED STATES PATENT OFFICE 2,426,964 ELECTRONIC ARC WELl jER Edwin M, Callender, Cynwyd, Pa., assignor to The Budd Company, Philadelphia, Pa., a cor-- poration of Pennsylvania Application July 15, 1944, Serial No. 545,063

This invention relates to arc welding apparatus. More particularly, the invention relates to direct current arc welding apparatus in which thepower is supplied from an alternating current source.

The objects of the invention may be mentioned as follows: the provision of a circuit and associated apparatus which will permit employment of an arc welding unit in conjunction with ordinary commercial alternating current voltages, such as 110 volts; the provision of circuit means which will permit current use from a commercial voltage source in wide ranges; the utilization of circuit arrangements which cooperate reduce the weight and increase the maneuverability of the equipment to an exceptional degree; the provision of arc welding apparatus which makes possible an eflicient substitution of electronic devices for rotating arc welding machinery; the provision of a circuit which lends itself to plural uses, such as welding, battery charging and the like; and in general the provision of a system of arc welding which is compact in physical structure and simple and efiicient in manipulation and welding action.

In order to set forth my invention, I have described hereinbelow certain modifications thereof which are shown in the accompanying drawings, of which:

Figure 1 is a wiring diagram of a preferred circuit;

Figure 2 is a diagram illustrating the circuit of Figure 1 as utilized for high current;

Figure 3 is a diagram of the arrangement of Figure 1 as utilized for low current;

Figure 4 is the general arrangement of Figure 1 modified to include a phase shift circuit as an auxiliary control feature;

Figures 5 and 6 are views illustrating families of curves, Figure 5 indicating the high voltage connections, and Figure 6 the low current connections;

Figure 7 is a view illustrating a method of cooling the ignitrons of the circuit; and.

Figure 8 is a modification of the circuit illustrating the adaptation of a three-phase'power source to the welding circuit.

In ordinary welding uses, it is not essential that the equipment used be light in weight and portable to an appreciable extent, since most welding operations are carried on under more or less stationary conditions. Recently, however, need has arisen, particularly in military operations in connection with aircraft and the like, for equipment which is readily portable, which is light and compact in physical set-up and which is adaptable for use on ordinary commercial voltages. To meet this general need and to fulfill the objects of the invention hereinabove stated, I have ascertained-that the use of power 8 Claims. (Cl. 315-205) rectifiers such as ignitrons is feasible in arc welding and that by a specially devised circuit I am able to employ commercial voltages to supplycurrent in ranges extending from as low as 10 amperes to as high as 300 amperes without modification of the circuit other than may be required by the movement of switches.

Referring to Figure 1 of the drawings, there is indicated a source I and 2 of commercial power which may be, for example, volts singlephase alternating current of (SO-cycle frequency. Current from this source is led through a main switch 3 to a main transformer 4 having a primary 5 and a secondary 6. Preferably the primary 5 is formed of a plurality of sections 1, 8, 9 and H], the ends of thes sections leading to terminals as shown ll, l2, l3, l4 and I5. The main leads I6 and I1 from the power source are adapted for connection to any one of the terminals H to l5 so that by proper placement, adjustment of the primary volta e may be made as desired.

Intermediate the taps II and i2 is positioned an auxiliary power circuit adapted for approximately 110 volts for supplying power to auxiliary equipment, such as the pump motor It for supplying cooling fluid to the ignitron circuit, th transformer H for supplying current to the fan motor 18, the pilot light I9 for indicating energization of the circuit and the transformer 20 adapted for supplying heating current to the filaments of the rectifier tubes.

The terminals 2| and 22 of the secondary 6 of the transformer 4 are each connected to ignitrons for supplying power to the welding circuit. The terminal 2| has connection to the anode 23 of the ignitron tube 24 and the terminal 22 has connection to the anode 25 of the ignitron 26. The cathodes of these two tubes numbered respectively 21 and 28 are connected together by grounded conductors 29. The igniters 30 and 3| of the ignitrons are normally energized by rectifier tubes 32 and 33, each tube includmg an anode 34 and cathode filaments 35 and a secondary coil 36 associated with the primary of transformer 20 in the auxiliary supply circuit. Resistors 31 are included in the anode circult of the rectifiers, the connection to these tubes being made from the anode to points 38 and 39 in the anode circuits of the ignitrons and from the igniters 3B and 3| directly to the filament circuit of the rectifiers. r

The welding electrodes 40 of the arc Welder 4| are placed in a branch circuit interposed between a point 42 on the conductor 29 and the mid-point 43 of the secondary'fi of transformer 4, thiscircuit connecting, the two ignitron cir. cuits so that voltage originating in the transformer 4 and passing through either ignitronhas a return circuit through the arc electrodes and the branch circuit between points 42 and 43. This branch circuit is designated by the numeral 44.

The branch circuit 44 includes, in addition to are electrodes 40, the reactor coil 45 and the tapped resistor 46, by means of which control of the circuit values may be obtained through shifting of the movable contact 4'! between the various terminals or resistor terminals 48 as indicated. There is also included in this circuit a switch 49 adapted to engage contacts 510, 5! and 52. Of these contacts, 50 has direct connection to the mid-point 43 of the transformer secondary 6, and

The operation of this preferred modification g of the invention may now be described.

It will first be assumed that high current values are desired for the arc welding circuits, such as may be included within a range of approximately 60 to 150 amperes. For this connection,

as previously indicated, the switch 49 is connected to the contact 50 and movable terminal 41 of the resistor 45 is adjusted to any desired predetermined terminal 48 effective to give the desired current value. If with this connection the main switch 3 is closed, power is at once transmitted to the transformer 4 which supplies current of alternating voltage to the ignitron circuits. Alternately, current will pass through ignitron 24 and ignitron 26 in each alternation, the return path of the current being through the return branch 44 including the arc welder 4L This current without the reactor 45 would be variable but unidirectional, but with the reactor the current assumes a more constant value due to the smoothing action of the reactor. The characteristics of the line source voltage, the arc voltage, the source current and the arc current are indicated in Figure 5 of the drawing for this high current connection. In this curve it is apparent that a substantial current of fair constancy flows between the arc electrodes 4!] which is unidirectional.

If it be desired to secure a current flow through the arc of low current value, the switch 49' is shifted to the contact 52 to secure the general connection, as shown in Figure 3 of the drawing. For this connection, it is apparent that current introduced by the transformer 4 i effective "only through the ignitron 24, since the return circuit 44 is now connected to the anode of the ignitron 26 preventing the development of voltage across this ignitron. With proper potential conditions, current will flow, during a given positive halfcycle, through ignitron 24 and through the branch circuit 44 to the point 22 of the secondary 6, as shown by the curves, the letters a and b indicating the positive and negative half cycles, respectively, as transmitted successively through the ignitrons 24 and 26. I-primary indicates the current variation in the primary 5 of the main transformer 4, and I-arc-a indicates the current flow through the ignitron 24 and the arc electrodes 4| during the specified a or positive half cycle. On the termination of the ource voltage half-cycle, however, current is cut off in the ignitron 24 circuit and drops to zero. Cessation 01''- current in the arc circuit is prevented, however, by the presence of the reactor 45 which supplies inductively stored energy to the branch circuit 44 in the local I) circuit including the ignitron 26. This local current flow is indicated by the curve I-arc-b, as shown in Figure 6, this curve being in continuation of the I-arc-a curve, and consequently indicating that a positive current continues to flow through the arc during the negative or bhalf cycle. The characteristics of the reactor are so chosen, in conjunction with the voltage and other characteristics, as to maintain during the half-cycle in which current ceases to flow through ignitron 24, a flow of current in branch 44. While this flow i declining according to the time constant of the circuit, nevertheless the magnitude is such as to maintain a substantial amount of current in the-arc electrode circuit and thus secure 0n the average a continuity in the arc welding current between half-cycles where normally the source voltage i ineiiective. This inductive current flow is maintained until the ignitron 24 strikes due to positive half-cycle voltage in the a circuit, as shown in the figure. The curve marked I-local-a is indicated as showing the reverse current flowing in the local-b circuit including the ignitron 26 during the inactive phase of ignitron 24.

I have indicated in Figure 4 a modification of the circuit arrangement of Figure 1 in that I utilize igniter control means for changing the striking point in the cycle of the source voltage. Referring to this figure, I have indicated the-secondary 60 corresponding to secondary 6 of transformer 4 with points 6| and 62 adjacent but displaced from the ends of the transformer connected to the anodes 63 of ignitrons 64 and 65. Similarly as in the case of the Figure 1 modification, the cathodes I36 of the ignitrons are connected together by a conductor 61 and grounded. Also, I have provided a branch shunt circuit 68 connecting midpoint E9 of the secondary 60 to the grounded connector 61, and in this branch circuit are positioned in series the arc electrodes of arc welder 76, the reactor H, the tapped resistor 72 provided with taps l3 and movable contact l4 and the contacts'lzi, l6 and H with the switch 78, by means of which current variation in the circuit may be made. Contact #6, as in the preferred modification, is connected to the point 62 through a resistor 79, and contact '16 is provided with a slide terminal in engagement with the resistor 19.

The elements of this circuit, as above mentioned, are substantially as shown in the Figure 1 modification. I have added to the statedelements, however, thyratron tubes 81 and 82', anodes in these tubes having connection through resistors 83' to the terminals 84 and 85- of the transformer secondary to. The cathodes ofthese thyratrons have connection to the igniters- 86 of the ignitrons. Each thyratron has a grid 81 energized by the secondaries 83' and 89; respectively, to which it is connected in series with the cathode of the tubes. These secondaries are energized by the primary 90 of the transformer 91, this primary having connection at one end to the point 69 on the transformer secondary 60 and at the other' end to a point-'91 intermediate a capacitor 92 and a variable resistor unit 93. The other terminal of the capacitor is connected to the anode of. the thyratron 8'2, and the other endofthe resistor 93 is connected to the anode of the thyratron 8!, the resistor and capacitor being in series. In order to secure a gradient of adjustment, the resistor 93 includes a rough adjustment variable resistor 94 and in parallel therewith a fine adjustment resistor 95.

Inspection of Figure 4 reveals the fact that the mid-point 89 divides the secondary of the transformer into two rectifier units each in conjunction with the capacitor 92 and resistor unit 93 forming branches of a phase change unit, the bridge of which extends from the transformer point 69 of secondary 60 to the point M on the conductor joining the capacitor 92 and the resistor unit 03. Consequently, it may be seen that for any given resistance value of the resistor unit 03 a definite phase value is given to the transformer 9| which is effective upon the grids 8'! on the thyratrons 8| and 82. By manual adjustment of the rough and fine variable resistors 94 and 05 of the resistor unit 93 the value of the phase difference between the grids 81 and the source voltage may be changed at will, and by such change the time period in which current flows in the ignitrons in any given half-cycle may be changed to supply variable heat energy at the arc electrodes.

It is, of course, apparent that this phase change adjustment is usable in conjunction with the major current adjustment secured by the variable resistor I2 and by the switch I8 in the branch circuit 68.

In Figure 8 there is illustrated a modification of the invention showing the application of a polyphase power source to arc welding in conjunction with the use of ignitrons. The numeral I indicates a three-phase power source by way of example, terminal connections being at tapped points, as IIJI, Current through this source is supplied to the various branch circuits I02, I03 and I04 including the secondaries of the threephase transformers, and in these various branch circuits are connected ignitrons I05, I06 and I01.

These ignitrons are of the usual gaseous-discharge type having an anode I08, a mercury cathode I09 and an igniter IIO. Associated with each ignitron are thyratron tubes III, H2 and H3, each of these tubes having an anode II4, a cathode H and a grid IIS, the anode of each thyratron being connected to the anode I08 of the associated ignitron through a resistor Ill, and the cathode of each thyratron having connection to the igniter IIO of each ignitron. The cathodes of each ignitron are connected to the return circuit II8 of the secondary system through a choke or reactor coil H9 and the electrodes I20 of the arc welder I2I so that current passing through each ignitron in phase passes also through the arc welder.

In order to control the heat energy supplied the arc welder, means are supplied to vary the point in the half-cycle of current flow through the ignitrons at which the tube strikes. This control is embodied in an induction voltage regulator unit I22 which comprises a primary rotor section I23 having'the primary coils I24, I25 and I26 and subject to'limited rotation by means of the hand wheel I21, and the stator element I28 having secondaries I29, I30'and I3I each related inductively to its associated primary coil. The primary coils I24, I25 and I26 are connected directly to the branch mains I02, I03 and I04, and the secondaries I29, I30 and I3I are connected respectively to the grids IIB of thyratron tubes III, H2 and H3. Accordingly, by manual adjustment of the rotor I23 of the unit relativeto the stator I28, the induction of the transformers and consequently the voltage as applied to th grids may be modified. Thus the time in the halfcycle of voltage as applied to the thyratron anode at which the thyratron strikes may thus be modified to secure a modification in the active period of current flow through the ignitrons and a control over the heat energy supplied to the arc electrodes.

It is pointed out that only a half wave of each phase is used in the diagrammatic showing of Figure 8, but adaptations may be readily made by employing inversely connected ignitrons in accordance with conventional practice for utilizing the full cycle of each phase branch. Also, it is evident that while the induction voltage regulator as described provides an effective heat control means, other equivalent means, such as a phase shift electrical bridge, may be used for the same purpose.

While emphasis has been laid upon the circuit arrangement and elements incorporated therewith, it is, of course, apparent that compactness is facilitated by structural arrangement and improvements in the accessory physical apparatus. For example, in the case of the ignitron tubes, while ordinary gravity circulation may be employed for cooling, the efficiency of the tubes may be increased considerably by employing forced circulation cooling methods, such as indicated in the arrangement of Figure 7. In this figure, the numerals I40 and MI indicate two ignitrons, and through theseignitrons is connected a cooling circuit including the fluid pump I42 and the heat radiator section I43. The radiator section I43 is cooled by means of an air current passing through the chamber I44, through the inlet I45 to the outlet I48, the air flow :being controlled by the fan I41 of motor I8, this motor receiving power from the branch circuit across primary coil I of transformer 4. By this means, a positive cooling of the current through the ignitrons is obtained which appreciably improves the efiiciency of the system.

While specified values and uses are hereinabove indicated, changes and modifications maybe made to accommodate the apparatus to particular requirement-s. For example, while a 60-cycle frequency of current is mentioned, operation of the system is not dependent upon this frequency. The two-part transformer including the primary and secondary is illustrated and described as separating the power source from the work circuit. I have found that an autotransformer is also usable and satisfactory for the purposes of my invention. The autotransformer has particular utility when weight is a factor of extraordinary importance.

Also while I have indicated rectifying diodes for the ignitrons, other rectifiers, such as the copper oxide type I shown in Figures 2 and 3, may be employed.

While the circuit described is primarily for the accomplishment of arc welding, a variety of other uses is possible, such for example as battery charging or application to rotating dynamoelectric equipment or the like.

In view of the various modifications and uses hereinabove referred to, I do not desire to limit my invention to the indicated disclosure, the elements of the invention being defined only by the scope of the claims hereto appended.

What is claimed is:

1. An arc welder system comprising power terminals, a transformer, a center tap connected to said transformer, rectifying" tubes", each having a cathodeand anode, connected with the cathodes joined together in opposition and across said transformer, welding electrodes and a reactor connected in series with each other between the center'tap of the transformer and. the tube cathodes to form a branch circuit through which current is transmitted from each rectifier in succession on application of alternating current power to said transformer, and switching means for shifting the connection of said branch circuit from the transformer center tap to the anode of one of said rectifying. tubes whereby said reactor is made efiective to discharge through the tube including said anode.

2. An arc welder system comprising power terminals, a transformer, a center tap connected to said transformer, rectifying tubes, each having a cathode and anode, connected with the cathodes joined together in opposition and across said transformer, welding electrodes and. a reactor connected in series with each other between the. center tap of the transformer and the tube cathodes, to form a branch circuit through which current is transmitted from each rectifier in succession on application of alternating current power to said transformer, switching means for shifting the connection of saidbranch circuit from the transformer center tap to the anode of one of said rectifying tubes whereby said reactor is made efiective to discharge through the tube including said anode, and a variable resistor in said branch circuit efiective-in either of said switch positions.

3. An are welder system comprising power terminals, a, transformer, a center tap connected to said transformer, rectifying tubes connected with the cathodes joined together in opposition and across said transformer, said tubes including a cathode, anode and control element, Welding electrodes connected between the center tap of the transformer and the tube cathodes to form a branch circuit through which current is transmitted from each rectifier in succession on application of alternating current power to said transformer, means connected with the tube control elements for passing alternate flow of current through said tubes, switching means for shifting the connection of said branch circuit from the transformer center tap to the anode of one of said rectifying tubes whereby said reactor is made efiective to dischargethrough the tube including said anode, and means including an energy storage device connected in series with said weldin electrodes for securing continuity-of curren t flow through said welding electrodes-when said switchis connected to the end terminal of said transformer. V

4. A power supply system comprising a source of alternating current, a load, an energy storage means connected to sai'd load, a first power rectifier connected to said source infparallelwith said load and storage means, a second power rectifier connected to said source in parallel with said load and storage means to supply power through the first rectifier to said load and storage means in intermittent half-cycles of source current flow and additional means'for supplying power to said load at will either from said source or from said storage means only through the second rectifier during "the time intervals between said intermittent half-cycle power supply.

5. A power supply system comprising a power source, a load, means including a'first rectifier tube for supplying energy: to. said load during intermittent half-'cyclesfromsaid power source,

additional: means including a second rectifier tube connected to said load for supplying power to said; load in the time interval between the half cycles of source supply, said additional means receiving and storing energy during the time periods when. energy is being supplied the load from said source, and means for varying the fraction. of the intermittent half cycles of sourcepowerapplicationin which said source is effective at the load.

6; An arc welder system comprising power terminals, a transformer, rectifying tubes connected in series across said transformer, said tubes including' a cathode, anode and control element, welding electrodes and a reactor connected in series with each other to form the branch circuit between an anode of one of said tubes and the tube cathodes, means connected with the tube control elements for causing alternate flow of current through said tubes, and a variable resistance connected in said branch circuit for'varying the power supply through said electrodes.

7'. A power supply system comprising a; power source, a load, means including a first rectifier tube for supplying energy to said load during intermittent half cycles from said power source, additional means including a second rectifier tube connectedv to said load for supplying power to saidi'load in the time interval between the half cycles of source supply, said additional means receiving and storing energy during the time periods when energy is being supplied the load from said; source, and means for varying the fraction of the intermittent half cycles of sourcepower application as well as the fraction of stored energy discharge in which the power is effective on the load, said last-named. means including a voltage regulator.

8.. An arc welder system comprising. power terminals, a transformer, rectifying tubes connected in series across said transform-e1, said tubes including a cathode, anode, and control element, welding electrodes and a reactor connected in series with each other to form a branch circuit between an anode of one of said tubes and the tube cathodes, and means connected with the tube elements for causing alternate now of current through said tubes, said transformer supplying current directly to one of said tubes only.

EDWIN M. CALLENDER.

REFERENCES CITED The following references are of record in the file of this patent:

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